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INSTALLATION MANUAL
Please read and study this manual completely before installation or use of any
Day4 Energy Inc. (Day4 Energy) photovoltaic modules. This manual applies to
the following products: Day4 Energy 36/ 48MC series photovoltaic modules.
INTRODUCTION
• To avoid the risk of electric shock and injury, be sure to completely
ground all Day4 Energy modules (US and Canada only).
With proper installation, operation and maintenance, Day4 Energy modules will
provide you with clean, renewable solar electricity for many years. This manual
contains important installation, maintenance and safety information. Retain
this manual for future reference. The word “module(s)” as used in this manual
refers to one or more Day4 Energy 36/ 48MC series photovoltaic modules.
• To avoid the danger of electric shock, fire and injury, do not disassemble
the Day4 Energy module, or remove any part installed by Day4 Energy
or any authorized dealer or integrator.
• Unauthorized persons should not open the cover of the junction box as
this increases chances of dangerous electric shock, may cause damage
to the module and will void the warranty. Only a qualified licensed
professional should attempt to open the cover of the junction box.
Disclaimer of Liability
Day4 Energy does not assume responsibility and expressly disclaims liability
for loss, damage or expense arising out of or in any way connected with
installation, operation, use or maintenance by using this manual. Day4 Energy
assumes no responsibility for any infringement of patents or other rights of
third parties which may result from the use of Day4 Energy modules. No license
is granted by implication or under any patent or patent rights. The information
in this manual is believed to be reliable, but does not constitute an expressed
and/or implied warranty. Day4 Energy reserves the right to make changes
to the product, specifications or manual without prior notice and on its sole
discretion.
• To avoid the risk of electric shock or injury, provide suitable protection
to prevent direct contact with solar electric systems with voltage
greater than 30V.
• Use caution when carrying Day4 Energy modules. It is recommended
that two or more persons carry the module by its frame and use nonslip gloves.
• Do not carry a Day4 Energy module by its connecting wires or junction
box.
• Do not drop anything on the surface of a Day4 Energy module. A
damaged surface can cause electric shock and injury.
General Information
• To avoid the hazard of electric shock and fire, be sure that all system
components are compatible with Day4 Energy modules. Components
should not subject the module to mechanical or electrical hazards.
The installation of photovoltaic Day4 Energy modules requires a great degree
of skill and should only be performed by qualified licensed professionals,
including, without limitation, licensed contractors and licensed electricians.
• Since sparks may occur, do not install the Day4 Energy module where
flammable gases or vapors are present.
WARNING
• Never leave a Day4 Energy module unsupported or unsecured.
• All instructions should be read and understood before attempting to
install, wire, operate or maintain the photovoltaic Day4 Energy module.
Contact with electrically active parts of the module such as terminals
can result in burns, sparks and lethal shock whether the module is
connected or disconnected.
• Do not drop a Day4 Energy module.
• Do not use or install a broken or damaged Day4 Energy module.
• Day4 modules with damaged back-sheets should never be installed or
operated.
• Some transformer-less inverters are not suitable for use with
photovoltaic modules in specific applications. Check with the inverter
manufacturer, the inverter installation manual and attain the inverter
manufacturer’s approval prior to use.
• To avoid the risk of fire or damage, do not artificially concentrate
sunlight on a Day4 Energy module.
• Do not touch the junction box terminals. This can cause electric shock
and injury.
• The installer assumes the risk of any injury that might occur during
installation, including, without limitation, the risk of electric shock and
or fire.
• Do not change the wiring of bypass diodes.
• Do not install Day4 Energy modules as a building integrated
photovoltaic (BIPV) module or above a flammable material.
• Day4 Energy modules generate DC electrical energy when exposed
to sunlight or simulated sunlight sources. Although a single module
produces only a low voltage and current, shocks and burns are still a
potential risk.
• Do not run reverse current through a Day4 Energy module in the
attempt to de-ice the module or for any other purpose.
• Do not stand or walk on the surface of a Day4 Energy module as you
may cause damage to the frame or other parts of the module.
• To avoid the danger of electric shock and injury, cover the front glass
surface of the Day4 Energy module with a dense, opaque material
during installation and handling.
CAUTION
• The shock hazard increases as Day4 Energy modules are connected in
parallel producing higher current. The shock risk increases as modules
are connected in series producing higher voltages.
• Use a Day4 Energy module for its intended purpose only. (Please refer to
the Day4 Energy 36/ 48MC warranty document.)
• To avoid reducing module function, damage, inoperable conditions and
other unknown troubles, do not treat the back-sheet or front surface
with paint or adhesives.
• To avoid the peril of electric shock, work only under dry conditions with
dry modules and tools.
• To avoid the risk of injury and damage to the module, do not stand or
step on a Day4 Energy module.
• Do not disconnect connectors under load.
• To avoid the threat of electric shock and/or fire, do not puncture or
damage the back-sheet of a Day4 Energy module. To avoid the peril of
electric shock and injury, children and unauthorized persons should not
be allowed near the installation of modules.
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GENERAL SAFETY
2. Observe the requirements described in sections of this manual labeled
“Installation” and “Specifications”.
Follow all permission, installation and inspection requirements.
3. Grounding of the Day4 Energy module frame is required. When ground
wires greater than 6 mmC (No. 10 AWG) are required the installer will
need to provide suitable terminal connectors.
• Before installing Day4 Energy modules, contact the appropriate
authorities to determine permissions, installation and inspection
requirements to be followed.
IEC 61730 Application Class A Information
• Electrically ground Day4 Energy modules for all systems of any voltage
(only applicable in the USA and Canada). If not otherwise specified it
is recommended that requirements of the latest National Electrical
Code (USA) or Canadian Electric Code (Canada) or any other applicable
national or international electrical standards be used.
(applies to Europe only):
Day4 Energy modules are designed to pass the criteria of application class A
requirements according to IEC 61730-part1.
To satisfy IEC 61730 requirements when installing the Day4 Energy modules be
sure to:
• Be sure that the construction or structure (roof, facade, etc.) where
the Day4 Energy modules are being installed has enough strength to
support the added module and structure weight. For modules that
are to be mounted on roofs, special construction or structures may be
required for proper installation. Both roof construction and module
installation design have an effect on the fire resistance of a building.
Improper installation may contribute to fire hazards. Additional devices
such as ground fault, fuses and disconnects may be required.
1. Use only double insulated stranded copper type cable. The cable should
be resistant to UV, water, ozone, fluids, salt, general weathering and
abrasion. The cable should be halogen free and flame retardant for
the Day4 Energy module and interconnect wiring. Be sure the cable is
certified according to IEC 60228 class 5.
2. Observe the requirements described in sections of this manual labeled
“Installation” and “Specifications”.
• Do not use Day4 Energy modules of different specifications in the same
system.
3. Equipotential bonding of the Day4 Energy modules and module frame
is recommended. The equipotential bonds between modules may only
be connected and approved by a qualified electrician.
• Follow all safety precautions of other system components used.
• Do not change or alter Day4 Energy modules or apply improper means,
such as, but not limited to, mirrors and/or other optical systems of
any kind. Do not operate the modules under artificially concentrated
sunlight such as an optical system and/or in direct contact with solar
thermal systems.
Option 1: Connect the module frame using cables [16 mmC (0.64
inC)] with cable lugs. Use the holes [diameter 4 mm (0.16 in)] for this
purpose. To create the conductive connection (frame is anodized),
use a self-tapping screw [diameter 5 mm (0.20 in)] or a serrated
washer.
Option 2: Create an electrical connection between the frames
and the mounting system by using serrated lock nuts (see
“Installation”, Figure 1 – Example B).
UL Listing Information
(applies to USA and Canada only):
To satisfy UL requirements when installing Day4 Energy modules be sure to:
4. Do not apply any external voltage higher than Voc labeled on the
module.
1. Use only stranded single-conductor wire of listed type USE-2, 12 AWG,
rated 90°C, 600 V, sunlight resistant for Day4 Energy modules and
interconnect wiring that is exposed to weather.
5. Refer to the module label for maximum series fuse rating.
INSTALLATION
• Please contact your Day4 Energy authorized representative with
questions regarding mounting profiles for modules.
General
• Please read this guide completely before installation or use of Day4
Energy modules. This section contains electrical and mechanical
specifications needed before using your modules.
Notes on Installation
• Clearance between the Day4 Energy module frame and the mounting
surface is required to allow cooling air to circulate around the back of
the module. This also allows any condensation or moisture to dissipate.
The module should never be sealed to the mounting surface with
sealant preventing air from circulating under the module.
• Do not mount damaged Day4 Energy modules.
• Day4 Energy modules should be firmly fixed in place in a manner
suitable to withstand all expected loads, including wind and snow
loads.
• In order to determine the maximum annual yield, the optimum
orientation and tilt of the Day4 Energy modules must be identified.
Sunlight shining vertically onto the modules will give the best
conditions to generate maximum power. To avoid performance drops
in series circuits, ensure all modules have the same orientation and tilt.
Modules should be of the same power class.
• Do not drill additional mounting holes into module frames, as this will
void the warranty.
• Day4 Energy modules must not be fitted as overhead or vertical glazing.
• Day4 Energy modules must be installed in a way that ensures the
junction box is in the uppermost position.
• Even the slightest partial shading like from dirt deposits will cause
a reduction in yield. A module is considered “shadow-free” if it is
un-obscured across its entire surface for the entire year. Even on the
shortest day of the year unobstructed sunlight should reach the
module.
• Day4 Energy modules should not be mounted without a frame.
Removal of the factory supplied frame is not permitted.
• The appropriate material should be used for mounting hardware to
prevent the module frame, mounting structure and hardware itself
from corrosion.
Please note that:
• Install Day4 Energy modules where they are not shaded by obstacles
like buildings and trees. Pay special attention to avoid partial shading
by objects during the daytime. Do not operate the module if it is
shadowed or otherwise covered in its entirety or partially by debris,
leaves, tree branches, dirt, bird droppings, snow, ice and/or any other
substance or objects capable of preventing the light from illuminating
the front surface of the module in a uniform unobstructed manner
(refer to section in this manual labeled “Notes on Installation”).
The recommended standoff height minimum to satisfy the UL fire class C
rating is 10.16 cm (4 in). Other mounting methods will affect the fire class
rating. The fire class rating of the PV module installation must meet the code
requirements as well as the requirements of the specific place of installation.
Please refer to Figure 1 for proper installation.
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FIGURE 1
FIGURE 2
EXAMPLE A:
CLAMPING ON
EXAMPLE A
EXAMPLE B:
BOLTING
EXAMPLE B
1
2
3
4
5
Stainless steel M8 nut
Stainless steel serrated washer
Aluminum clamping plate
EPDM washer 2mm (0.78 in)
Stainless steel M8 t-head bolt
It is recommended that a torque wrench be used for installation. In Figure 1 - Example A the tightening torque (using stainless steel M8 bolts) should be
approximately 15-20 Nm (11-15 ft-lb). Use the existing holes for securing the module. Do not drill additional holes as doing so would void the warranty. Use
appropriate corrosion-proof fastening materials.
Each module must be securely fastened at a minimum of 4 points. The frame has been stress tested for mounting on the long sides. The module must not be
secured by its short sides. This method offers maximum loading capacities on the module surface. (See Figure 2)
Europe only: Day4 Energy modules have been evaluated by third party testing for a maximum positive design loading of 5400 N/mC and a maximum
negative design load of 2400 N/mC.
USA and Canada only: Day4 Energy modules have been evaluated by UL for a maximum positive or negative design loading of 1436.4 N/mC (30 lbs/ftC).
Day4 Energy modules have been evaluated by UL for mounting using the four provided mounting holes in the frame (refer to Figure 2 – Example B).
WIRING
Day4 Energy Module Wiring
• The maximum number of Day4 Energy modules that can be wired
in series or parallel design is dependent on legal requirements,
maximum current and voltage ratings as indicated on the module
label, installation design, space and further specifications of additional
equipment such as inverters and converters.
General
All wiring methods should be in accordance with the NEC in USA or CEC in
Canada or any other code, electrical code, law or bylaw applicable for the place
of installation.
• All wiring should be completed by a qualified licensed professional.
• Day4 Energy modules must have the same amperage when connected
in series. When connected in parallel, the modules must have the
same voltage. The modules must not be connected together to create
a voltage higher than the permitted system voltage according to
protection class A.
• Wiring should be protected to help ensure personal safety and to
prevent damage.
• All Day4 Energy modules connected in series should be of the same
model class and/or type.
• The Day4 Energy 48MC series modules can be used for “off-grid”
installations, like charging batteries, if electronic equipment such as
a power tracker is used to control module output parameters and
provides accurate electrical output according to off-grid appliance
specifications.
• Do not connect Day4 Energy modules in parallel without using a
connection box.
• Cable used for any wiring should be sized according to applicable
electrical codes.
• Any cable used in the installation should conform to the requirements
of IEC 60228 class 5 (Europe only).
• Please contact your local licensed installer regarding the use of
Day4 Energy 48MC series modules in off-grid applications and in
combination with charge controllers or similar equipment.
• Day4 Energy modules contain factory installed bypass diodes. If these
modules are incorrectly connected to each other the bypass diodes,
cables or junction boxes may be damaged.
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DIODES
Array Wiring
The term “array” is used to describe the assembly of several Day4 Energy
modules on a support structure with associated wiring. Use insulated copper
wire that is suitable for outdoor use and is insulated to withstand the
maximum possible system open circuit voltage. Check local codes for further
requirements.
Bypass Diodes
Day4 Energy modules in series strings that are partially shaded may cause
reverse voltage across cells or modules because current from other cells in
the same series is forced to flow through the shaded area. This may cause
undesirable heating to occur. The use of a diode to bypass the shaded area can
minimize both heating and reduce the array current.
Earth Ground Wiring
All Day4 Energy modules are equipped with factory installed bypass diodes.
The factory installed diodes provide proper circuit protection for the systems
within the specified system voltage so that no other additional bypass diodes
are required. Contact your authorized Day4 Energy representative for the
proper diode type if it is necessary to add or change diodes due to system
specifications. Refer to the module label for correct diode size.
(applies to USA and Canada only)
Ground should be carried out by securing the Day4 Energy module or array
frame to avoid the hazards of electric shock or fire. The array frame should be
grounded in accordance with NEC Article 250 (USA) or CEC (Canada). Contact
local authorities to determine the necessary grounding code requirements.
Proper grounding is achieved by connecting the module frames and structural
members contiguously together using a suitable “grounding conductor”. It
is recommended to utilize a UL listed grounding lug made of stainless steel.
Use a tin-plated or beryllium grounding lug if the grounding method involves
attachment of a grounding lead to the module frame.
Standard Operating Conditions
It is recommended that Day4 Energy modules be operated under
“Standard Operating Conditions” (SOC).
An installation location with conditions different from SOC or with other
“Special Conditions” (see below) should be avoided. SOC of Day4 Energy
modules are as follows:
The grounding conductor, grounding lead, or strap may be copper, copper
alloy, or another material acceptable for use as an electrical conductor per
NEC/CEC. The grounding conductor must make a connection to earth using a
suitable earth ground electrode. Ensure positive electrical contact through the
anodizing on the module’s frame by utilizing one of the following grounding
methods:
1.) Standard Operating Conditions
• The Day4 Energy module should be operated only in terrestrial
applications. No space or other “Special Conditions” (see below).
Attach the grounding conductor:
• The operating temperature of the module should be within -40°C
(-40°F) to 90°C (194°F).
1. To one of the 4 mm (0.16 in) holes marked ‘ground’ with a nut, bolt or
screw assembly and a serrated washer, external toothed washer, or
a paint piercing washer for attachment of the grounding lug to the
Day4 Energy module frame.
• The relative humidity should be within 45% to 85%.
• The installation place should be less than 1,000 m (3,280 ft) above sea
level. Installations more than 1,000 m (3,280 ft) are allowed only if the
wind pressure load for a module is less than 2,170 N/mC (45 lbs/ftC).
2. To electrically conductive metal, such as that of a support structure
which has been bonded to the module frame through a bonding or
external tooth washer, or a welded, or a soldered for brazed joint or
other suitable means as described above.
2.) Special Conditions
3. With two or more screws or two full threads of a single screw
engaging the module frame metal.
• Operating temperature and installation place conditions are different
from SOC.
Attention: Do not allow dissimilar metals such as copper and aluminum to
come in contact with each other. Use grounding lugs made of stainless steel,
beryllium or tin-plated. Never use self-tapping screws to connect the grounding
conductor.
• The salt damage is extreme at the installation location.
• The hail and snow damage is severe at the installation location.
• The sand and dust damage is severe at the installation location.
• The air pollution, chemically active vapors, acid rain, soot, or other
pollutants are extreme at the installation location.
Day4 Energy Module Terminations
A junction box as a terminal enclosure is equipped for electrical connections on
Day4 Energy modules. Day4 Energy modules are equipped with Tyco Solarlok
Interconnection Systems in either UL compliant or IEC compliant versions,
output cables, and male and female cable couplers. Use the Tyco Solarlok
couplers for electrical connections only.
Please contact your Day4 Energy authorized representative with questions
regarding other electrical connections for Day4 Energy modules.
Junction Box and Terminals
Day4 Energy modules are equipped with one junction box with terminals
for both positive and negative polarity and bypass diodes. One terminal is
dedicated to each polarity with the polarity symbols engraved onto the body of
the junction box. No modifications to the junction box are permitted.
Conduit
For applications where wire conduits are used, follow the applicable codes for
outdoor installation of wires in conduits. Verify that all fittings are properly
installed to protect wires against damage and prevent moisture intrusion.
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SPECIFICATIONS
MAINTENANCE
Notes on Specification
Some maintenance is recommended to maintain optimal output performance
of the Day4 Energy modules. If the module surface becomes dirty, it may reduce
output power. It is recommended to clean the surface of the module with
plenty of water and a soft cloth or sponge. A mild non-abrasive detergent may
be applied for persistent dirt. Never scratch or rub away any dirt when dry. Do
not use a high pressure cleaner or automated cleaning equipment.
• Rated electrical characteristics are within 3.5% of the values measured
at Standard Test Conditions (STC). STC are: Irradiance of 1000 W/mC, 25°C
cell temperature and solar spectral irradiance per IEC 60904-3 (AM1.5
solar spectral irradiance).
• The current output for the Day4 Energy modules is shown in the
Specifications as measured at Standard Test Conditions. These
conditions may not be frequently observed in actual practice.
It is also recommended to inspect the Day4 Energy module’s electrical and
mechanical connections annually. All fastenings should be tight and secure and
free of corrosion. All cable connections should be secure, tight, clean and free of
corrosion. Cables may not be damaged in any way.
• Under normal conditions a Day4 Energy module may experience
conditions that produce more current and/or voltage than reported at
Standard Test Conditions. Accordingly, the values of Isc and Voc marked
on listed module should be multiplied by a safety factor of 1.25 when
determining voltage ratings, conductor capacities, fuse sizes, and size of
controls connected to the module output.
To avoid the risk of electric shock and/or injury, it is recommended an
authorized professional carry out the electrical and/or mechanical inspection
and/or maintenance is required. Take care that the lid of the junction box is
tightly secured and electrical connectors are properly connected and free of
corrosion.
If modules are stored prior to installation, ensure that no water, dirt, dust,
etc. accumulates on the module’s back side. The contacts and the junction
box especially, must be kept free of any moisture. Inside storage is strongly
recommended.
Electrical ratings at STC:
Maximum system voltage rating:
(V) IEC 61215/ IEC61730 rating = 1000; (V) UL 1703 rating = 600
Day4 36MC
Maximum
power rating
(W)
115
120
125
130
135
140
145
Voltage
rating (V)
Current
rating (A)
16.80
16.95
17.21
17.55
17.78
17.98
18.24
6.89
7.08
7.30
7.46
7.60
7.79
7.95
Voltage
rating (V)
Current
rating (A)
22.30
22.60
22.95
23.04
23.40
23.70
23.82
24.00
6.97
7.08
7.19
7.38
7.48
7.60
7.77
7.92
Short circuit
current
rating (A)
7.60
7.70
7.90
8.05
8.10
8.20
8.30
Open circuit
voltage
rating (V)
20.98
21.23
21.52
21.90
22.05
22.28
22.57
Short circuit
current
rating (A)
7.55
7.70
7.80
7.90
8.05
8.10
8.20
8.30
Open circuit
voltage
rating (V)
28.00
28.30
28.60
28.80
29.20
29.40
29.51
29.70
The return of any Day4 Energy module will not be accepted by Day4 Energy
unless prior written authorization has been given by Day4 Energy.
As part of our policy of continuous improvement Day4 Energy reserves the right
to change product specifications at any time without prior notice and its sole
discretion.
Day4 48MC
Maximum
power rating
(W)
155
160
165
170
175
180
185
190
USA: Refer to Section 690-8 of the U.S. National Electrical Code for an additional
multiplying factor of 1.25 which may be applicable.
Manufactured by Day4 Energy Inc.
#401, 4621 Canada Way, Burnaby, BC Canada V5G 4X8
office: 604 297 0444
fax:
604 297 0445
email: [email protected]
web: www.day4energy.com
Specifications and design are subject to change without notice. The features, functions and appearance
of Day4 MC modules may differ from details given due to continual product development. For updated
documentation please contact Day4 Energy Inc. or check our web site: www.day4energy.com.
Installation_Manual_111209_EN_SNGL
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